Preview

Design, Fabrication and Application of Minimum Quantity Lubrication (Mql) Setup in Machining

Powerful Essays
Open Document
Open Document
6598 Words
Grammar
Grammar
Plagiarism
Plagiarism
Writing
Writing
Score
Score
Design, Fabrication and Application of Minimum Quantity Lubrication (Mql) Setup in Machining
A Report On

Design, Fabrication and Application of Minimum Quantity Lubrication (MQL) Setup in Machining

By

Saurav Chakraborty
IIT Bhubaneswar

Under the supervision of

Dr. Sudarsan Ghosh
Associate Professor Department of Mechanical Engineering IIT Delhi

July 2013

Certificate
This is to certify that Mr. Saurav Chakraborty, student of B.Tech (Mechanical Engg.) 3rd Year, IIT Bhubaneswar, has done his project under my guidance during the period 16 May-11 July, 2013 (8 weeks). He has worked on the project titled, “Design, Fabrication and Application of Minimum Quantity Lubrication (MQL) Setup in Machining” at the Machine Tool and Metrology Laboratories, Department of Mechanical Engineering, Indian Institute of Technology, Delhi He has abided by the rules of the institute and has finished all tasks assigned to him to my satisfaction.

Dr. Sudarsan Ghosh
Associate Professor Department of Mechanical Engineering Indian Institute of Technology, Delhi Hauz Khas, New Delhi-110016

Abstract Environmental concerns call for the reduced use of cutting fluids in metal cutting practice. Minimum quantity lubrication (MQL) machining is one of the promising solutions to the requirement for decrease in cutting fluid consumption. This paper reports the results of an experimental work to investigate the effect of a well-designed MQL set up on machining constraints like tool forces and surface finish. It was found that machining with the MQL set up produced better results in terms of lesser cutting forces and better surface finish in comparison to dry and wet machining.

Keywords: MQL machining, Nozzle design, cutting force, Surface finish

Acknowledgement This work has been completed under the guidance of the following members of IIT Delhi: Faculty Members 1. Dr. Sudarsan Ghosh (Mechanical Dept.) Email: ghoshs@mech.iitd.ac.in 2. Dr. Sitikantha Roy (Applied Mechanics Dept.) Email: sroy@am.iitd.ac.in 3. Dr. Sawan Suman (Applied Mechanics Dept.) Email:



References: 1. Graham D (2000) Dry out. Cutting Tool Eng 52: 1–8 2. Balulescu M, Herdan JM. (1997), Ecological and health aspects of metalworking fluids’ manufacture and use 3. M. C. Shaw, Metal Cutting Principles, 2nd Edition ed. Arizona: Oxford University Press, 2005. 4. E. O. Ezugwu, J. Bonney, and Y. Yamane (2003), An overview of the machinability of aeroengine alloys, Journal of Materials Processing Technology, 134 233-253. 5. E. O. Ezugwu et.al. (2005), Key improvements in the machining of difficult-to-cut aerospace superalloys, International Journal of Machine Tools and Manufacture 45 13531367. 6. Balulescu M, Herdan JM (1997), Ecological and health aspects of metalworking fluids manufacture and use 7. Suda S et.al. (2002), Developments in cutting fluids for MQL cutting, Journal of Japanese Society of Tribologists, 47/7: 550-556. 8. N. N. (1996), Biodegradable Fluids and Lubricants, Industrial Lubrication and Tribology, 48/2 17-26. 9. Suda, S., Yokota, H., Inasaki, I., Wakabayashi, T. (2002), A Synthetic Ester as an Optimal Cutting Fluid for Minimal Quantity Lubrication Machining, Annals of the CIRP, 51/1 95-98. 10. Klocke F, Eisenblaetter G (1997), Dry cutting. Ann CIRP 46(2): 519–526 11. Ueda T, Nozaki R, Hosokawa A (2007), Temperature measurement of cutting edge in drilling – effect of oil mist 12. Khan MMA, Dhar NR (2006), Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI-1060 steel 13. Dhar NR, Ahmed MT, Islam S (2007), An experimental investigation on effect of minimum quantity lubrication in machining AISI 1040 steel 14. Kuan-Ming Li K-M, Liang SY (2007), Modelling of cutting forces in near dry machining under tool wear effect 15. Dhar NR, Islam S, Kamruzzaman M (2007), Effect of minimum quantity lubrication(MQL) on tool wear, surface roughness and dimensional deviation in turning AISI-4340 steel 16. Filipovic A, Stephenson DA (2006), Minimum quantity lubrication (MQL) applications in automotive power-train machining 17. Braga DU, Diniz AE, Miranda GWA, Coppini NL (2002), Using a minimum quantity of lubricant (MQL) and a diamond coated tool in the drilling of aluminium– silicon alloys 18. Davim JP, Sreejith PS, Silva J (2007), Turning of Brasses Using Minimum Quantity of Lubricant (MQL) and Flooded Lubricant Conditions 19. Viktor P. Astakhov,(2008), Ecological Machining: Near-dry Machining, General Motors Business Unit of PSMI, 1255 Beach Ct., Saline MI 48176, USA. 24. N. R. Dhar , M. Kamruzzaman, Mahiuddin Ahmed (2006), Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel, Journal of Materials Processing Technology 172 299–304 25. M.Z.A.Yazid et.al. (2011), Surface integrity of Inconel 718 when finish turning with PVD coated carbide tool under MQL, Procedia Engineering 19 396 – 401

You May Also Find These Documents Helpful

  • Powerful Essays

    a) In machining, material is removed from the workpart so that the remaining material is the desired part geometry.…

    • 1626 Words
    • 7 Pages
    Powerful Essays
  • Better Essays

    4140 Steel Lab Report

    • 1640 Words
    • 7 Pages

    Heat treating steels to increase their hardness strength has been a process that has been done for centuries. In addition to this, reasoning was found for why it is uncommon to see heat treatment in materials with low carbon content, such as low carbon steels (1018 steel) and brass. The results of this experiment coincide with what was expected, and no obvious errors in the experiment were found. One factor of this experiment that could be improved is the quality of the micrographs that were produced. To do this, the metallurgical preparation of the material would need to be done in a much more precise and consistent way. The instructions were clearly laid out, but the execution of the instructions varied too much between individual samples, and consequently produced lackluster images for analysis. In the future, some recommendations to improve the quality of the finished surfaces could be to keep fresh abrasive pads on the ECOMET polishing machines, taking extra care when preparing and handling the etching solutions, and observing the surface finish of the material directly after the etching process is…

    • 1640 Words
    • 7 Pages
    Better Essays
  • Powerful Essays

    Communication is a process where we share our feelings, thoughts, experience, ideas, suggestions, and feedback.…

    • 1021 Words
    • 4 Pages
    Powerful Essays
  • Powerful Essays

    Progress Report submitted in partial fulfillment of The requirements for the Bachelor of Engineering (Hons) (Mechanical Engineering)…

    • 4220 Words
    • 17 Pages
    Powerful Essays
  • Good Essays

    • Baig, M.W.;Naqvi, M.A.; &Qureshi, M.U.,Automobile &Production Engineering,VSRD International Journal of mechanical, 2012 retrieved from, http://www.vsrdjournals.com/ME/Issue/2012_08_August/Web/4_MW_Baig_837_Research_Communication_ME_August_2012.pdf.…

    • 674 Words
    • 3 Pages
    Good Essays
  • Satisfactory Essays

    Week 8 Reflective Report

    • 399 Words
    • 2 Pages

    I always think of a drillpress and mill when this opration comes in my mind. Knowing the type of metals your trying to cut can be importan to know for the right cutters to use I always know with the drillpress the larger the bit trying to dill the slower the speed and the small the bit the higher the speed. I never knew to info on the coatings on the bits but I did learn now about cobalt and tungsten being coated now to make the cutters harder even at high tempetures.…

    • 399 Words
    • 2 Pages
    Satisfactory Essays
  • Satisfactory Essays

    Agatha Christie was born in the 1890's in England. Her father showed her to read and write. She loved it ever since and she's written books and those books got turned into movies. Her first book was published in 1920 with a character that she used in 33 other novels and 54 short stories. She is the world's best mystery authors.…

    • 255 Words
    • 2 Pages
    Satisfactory Essays
  • Powerful Essays

    Ezutah Udoncy Olugu and 2Kuan Yew Wong Department of Manufacturing and Industrial Engineering, Faculty of Mechanical Engineering, University Technology Malaysia, 81310 UTM Skudai, Malaysia…

    • 7299 Words
    • 30 Pages
    Powerful Essays
  • Good Essays

    In MAF, a flexible finishing action is sustained by the pressure exerted by a blanket of abrasive bonded to iron particles. This mixture is actuated by a magnetic field, which is coupled with rotational and oscillatory motions between flexible MAF brush and work piece. The finishing process is essentially accomplished without the need for designing expensive, rigid, vibration free machine tools by incorporating magnetic machining elements necessary cost of new equipment. MAF cutting agent is a composite of fine abrasive grits and coarser iron grains. The particles can thus be excited by a strong magnetic field to generate a normal dynamic pressure sufficient to refine the surface, deburr and chamfer its edges. Conventional abrasives like aluminum oxide (Al2O3)…

    • 5357 Words
    • 22 Pages
    Good Essays
  • Better Essays

    [4] J. S. Soni, G. Chakraverti, Machining characteristics of titanium with rotary electro-discharge machining, Wear, 171 (1994) 51-58.…

    • 13816 Words
    • 56 Pages
    Better Essays
  • Powerful Essays

    Alberdi studied a machinability model in composite materials. The machinability index for various composite materials with different thicknesses was found experimentally, which showed very different results for different materials. A study of the effect of the abrasive water jet process parameters on the quality of cut (taper and surface roughness) was carried out. The results showed that composite materials have a significantly higher machinability index than metals (e.g., Aluminium 2024 has a machinability index of 215.3, and stainless steel 316 82.5), which means that composite materials can be cut significantly faster than metals.…

    • 1950 Words
    • 8 Pages
    Powerful Essays
  • Better Essays

    VM5800

    • 459 Words
    • 7 Pages

    VM5800 Stationary Valve Grinding and Lapping Machine FEATURES • COMPONENTS & ACCESSORIES • TECHNICAL DATA Modular machine configuration for grinding, lapping and face turning of sealing surfaces Grinding and lapping up to DN 250 mm (9.8 inches), with optional equipment, up to DN 350 mm (13.8 inches) Swiveling Operator’s Panel with ergonomic sub-division of all operating elements, digital displays, timer, etc. Vertical adjustment of the spindle and mounting of the optional facing head takes only a few seconds due to quickclamping couplings.…

    • 459 Words
    • 7 Pages
    Better Essays
  • Satisfactory Essays

    Lab Lathe

    • 629 Words
    • 2 Pages

    For all metal cutting process,Speed and feeds are important parameters.The colloquial term ‘speeds and feed’ refers to the speed,feed and depth of cut of a metal cutting process.To describe these paraneters,we will be using turning process.The figure shows the important geometry.The speed is cutting speed,which is a measure of the part cut surface speed relative to the tool.…

    • 629 Words
    • 2 Pages
    Satisfactory Essays
  • Satisfactory Essays

    M4 FUNCTION

    • 430 Words
    • 2 Pages

    1. REFERENCES: Lubricate order (LO); STP 21-1-SMCT; TM 9-1005-319-10; and DA From 2404, Equipment Inspection and Maintenance Worksheet.…

    • 430 Words
    • 2 Pages
    Satisfactory Essays
  • Better Essays

    Corrosion

    • 2815 Words
    • 12 Pages

    Corrosion, wear and corrosive wear; the story of lubrication systems in large technology object storage and use…

    • 2815 Words
    • 12 Pages
    Better Essays